Method for producing positive electrode active material for nonaqueous electrolyte secondary battery

ABSTRACT

A method for producing a positive electrode active material for a nonaqueous electrolyte secondary battery includes crystallizing a nickel-cobalt-manganese composite hydroxide by neutralizing a salt containing at least nickel, a salt containing at least cobalt, and a salt containing at least manganese; and firing a lithium mixture obtained by mixing the nickel-cobalt-manganese composite hydroxide with a lithium compound in an oxygen atmosphere to obtain a lithium-metal composite oxide, wherein in the crystallization process, an oxygen concentration in an atmosphere above a solution surface of the aqueous reaction solution is controlled in a range of 0.2% to 2% by volume, a temperature of the aqueous reaction solution is controlled between 38° C. to 45° C., a pH value of the aqueous reaction solution is controlled between 11.0 to 12.5, and a dissolved nickel concentration in the aqueous reaction solution is controlled in a range of 300 mg/L to 900 mg/L.

CROSS-REFERENCE TO RELATED APPLICATION

The application is a divisional of U.S. patent application Ser. No.16/320,730 filed on Jan. 25, 2019, which is a U.S. National Stage ofInternational Application No. PCT/JP2017/027537 filed on Jul. 28, 2017,each of which claims benefit of Patent Application No. 2016-150621 filedin Japan on Jul. 29, 2016, the entire contents of which are herebyincorporated by reference.

TECHNICAL FIELD

The present invention relates to a positive electrode active materialfor a nonaqueous electrolyte secondary battery and a method forproducing the same, as well as a nonaqueous electrolyte secondarybattery.

BACKGROUND ART

With the recent wide spreading use of portable devices such as a mobilephone and a notebook personal computer, there has been a strong demandto develop a small and light secondary battery having a high energydensity. Also, corresponding to the increase in an environmentalconsciousness, development of an eco-friendly car called XEV which emitsless CO₂ is progressing. As the characteristics required in thesecondary battery for the eco-friendly car, an increase in the runningdistance per one charge and an excellent cycle characteristic uponrepeat of charging and discharging operations may be cited. Accordingly,the secondary batteries to be used in these uses are required to have afurther high energy density as well as an excellent cyclecharacteristic.

As the secondary battery having a high energy density, a nonaqueouselectrolyte secondary battery may be cited. As a representative batteryof the nonaqueous electrolyte secondary battery, a lithium ion secondarybattery may be cited. In a positive electrode material of the lithiumion secondary battery, a lithium-metal composite oxide is used as apositive electrode active material. A lithium-cobalt composite oxide(LiCoO₂) can be synthesized comparatively easily, and in addition, thelithium ion secondary battery using the lithium-cobalt composite oxideas the positive electrode active material can generate a high voltage ofa 4-V class, so that the lithium-cobalt composite oxide has been put inpractical use as the positive electrode active material which canrealize the secondary battery having a high energy density.

However, because cobalt is rare and expensive, oxides using nickel,which is cheaper than cobalt, such as a lithium-nickel composite oxide(LiNiO₂) and a lithium-nickel-cobalt-manganese composite oxide(LiNi_(0.33)Co_(0.33)Mn_(0.33)O₂), have been developed. Among them, thelithium-nickel-cobalt-manganese composite oxide has drawn attentionbecause it is comparatively cheap and has an excellent balance amongheat stability, durability, and so forth. However, further enhancementof the energy density and improvement in the cycle characteristic aredemanded.

Corresponding to the demands of improvement in the energy density andcycle characteristic in the positive electrode active material, variousproposals have been made. In order to improve the cycle characteristicand to realize a high output, for example, Patent Literature 1 proposesthe positive electrode active material for a nonaqueous electrolytesecondary battery, the average particle diameter thereof being in therange of 2 to 8 μm, and [(D90−D10)/average particle diameter] that is anindicator to represent a spread of the particle size distributionthereof being up to 0.60. It is considered that the active material likethis has a high capacity and a long durability because this materialundergoes an electrochemical reaction uniformly.

Patent Literature 2 proposes the positive electrode active material fora nonaqueous electrolyte secondary battery; the material containingsecondary particles formed of flocculated primary particles of thelithium-nickel composite oxide; the primary particle having on thesurface thereof a coat layer of an inorganic lithium compound or thesecondary particle having a void inside thereof; and a ratio of an areaoccupied by the coat layer or by the void to a cross section area of thesecondary particle being in the range of 2.5% to 9%. It is consideredthat by using the positive electrode active material like this, thesecondary battery having high initial charging and dischargingcapacities as well as an excellent cycle durability can be obtained.

CITATION LIST Patent Literatures

[Patent Literature 1] Japanese Unexamined Patent Application PublicationNo. 2011-116580

[Patent Literature 2] Japanese Unexamined Patent Application PublicationNo. 2010-080394

SUMMARY OF INVENTION Technical Problems

However, in the positive electrode active material of Patent Literature1, because the fillability of the positive electrode active material islow, it cannot be said that the volume-based energy density thereof ishigh. On the other hand, in the positive electrode active material ofPatent Literature 2, because the voids are formed in entire of thesecondary particle, these voids act as a resistance, thereby resultingin an increase in the reaction resistance of the battery and a decreasein the charging and discharging capacities. In addition, this activematerial has the coat layer of an inorganic lithium compound on thesurface of the primary particle thereby causing an increase in thereaction resistance of the secondary battery to be obtained.

The present invention was made in view of the problems described above.Therefore, provided by the present invention are: a positive electrodeactive material with which a nonaqueous electrolyte secondary batteryhaving high charging and discharging capacities as well as suppresseddeterioration of the charging and discharging capacities even uponrepeating the charging and discharging operations can be obtained; and anonaqueous electrolyte secondary battery containing the positiveelectrode active material in the positive electrode thereof.

In addition, the present invention has an object to provide a cheap andconvenient production method of the above-mentioned positive electrodeactive material for a nonaqueous electrolyte secondary battery even inan industrial scale.

Solution to Problems

The inventors of the present invention intensively studied improvementin the charging and discharging capacities of the nonaqueous electrolytesecondary battery as well as the cycle characteristic thereof and havefound out that the charging and discharging capacities and the cyclecharacteristic can be improved when the positive electrode activematerial has a specific particle structure. In addition, they have foundout that the particle structure of the positive electrode activematerial is significantly dependent on production conditions of acomposite hydroxide, which is a precursor thereto, and that the particlestructure of the positive electrode active material can be controlledwhen the composite hydroxide obtained under a specific crystallizationcondition is used in the production of the positive electrode activematerial. With these findings, the present invention has been completed.

A first aspect of the present invention provides a positive electrodeactive material for a nonaqueous electrolyte secondary battery, in whichthe material includes a lithium-metal composite oxide represented by ageneral formula: Li_(a)Ni_(x)Co_(y)Mn_(z)M_(t)O_(2+α) (0.95≤a≤1.50,0.30≤x≤0.70, 0.10≤y≤0.35, 0.20≤z≤0.40, 0≤t≤0.1, x+y+z+t=1, and 0≤α≤0.5;and M is at least one element selected from Ti, V, Cr, Zr, Nb, Mo, Hf,Ta, Fe, and W) and containing a secondary particle formed of a pluralityof flocculated primary particles. A void ratio obtained from an imageanalysis result of a cross section of the secondary particle, the imagethereof being obtained by a scanning electron microscope, is at least 5%and up to 50% in a first area that is from a central part of thesecondary particle to one half of a radius of the secondary particle,and is up to 1.5% in a second area that is outside the first area.

In the positive electrode active material, the void ratio in the firstarea is preferably at least 5% and up to 20%. In addition, in thepositive electrode active material, a tap density is preferably at least2.0 g/cm³ and up to 2.6 g/cm³. In addition, in the positive electrodeactive material, a volume-average particle diameter MV is preferably atleast 5 μm and up to 20 μm, and [(D90−D10)/average particle diameter]that is an indicator to represent a spread of particle sizedistribution, is preferably at least 0.7.

A second aspect of the present invention provides a nonaqueouselectrolyte secondary battery including a positive electrode includingthe positive electrode active material for a nonaqueous electrolytesecondary battery as described above.

A third aspect of the present invention provides a method for producinga positive electrode active material for a nonaqueous electrolytesecondary battery, in which the material is represented by a generalformula: Li_(a)Ni_(x)Co_(y)Mn_(z)M_(t)O_(2+α) (0.95≤a≤1.50, 0.30≤x≤0.70,0.10≤y≤0.35, 0.20≤z≤0.40, 0≤t≤0.1, x+y+z+t=1, and 0≤α≤0.5; and M is atleast one element selected from Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, Fe, andW) and containing a secondary particle formed of a plurality offlocculated primary particles; and the method includes a crystallizationprocess of crystallizing a nickel-cobalt-manganese composite hydroxideby neutralizing a salt containing at least nickel, a salt containing atleast cobalt, and a salt containing at least manganese in an aqueousreaction solution, and a firing process of firing a lithium mixtureobtained by mixing the nickel-cobalt-manganese composite hydroxide witha lithium compound in an oxygen atmosphere to obtain a lithium-metalcomposite oxide; and in the crystallization process, an oxygenconcentration in an atmosphere above a solution surface of the aqueousreaction solution is controlled in a range of at least 0.2% by volumeand up to 2% by volume, a temperature of the aqueous reaction solutionis controlled in a range of at least 38° C. and up to 45° C., the pHvalue of the aqueous reaction solution is controlled in a range of atleast 11.0 and up to 12.5 based on the solution temperature of 25° C.,and a dissolved nickel concentration in the aqueous reaction solution iscontrolled in a range of at least 300 mg/L and up to 900 mg/L.

It is preferable that the crystallization process include continuouslyadding a mixed aqueous solution including nickel, cobalt, and manganeseinto a reaction vessel, and overflowing slurry includingnickel-manganese composite hydroxide particles formed by neutralizationto recover the particles. In addition, in the crystallization process,it is preferable that concentration of the mixed aqueous solution rangefrom at least 1.5 mol/L and up to 2.5 mol/L. In the firing process, itis preferable that firing be carried out at a temperature of at least800° C. and up to 1000° C. In addition, in the firing process, it ispreferable that lithium hydroxide, lithium carbonate, or a mixture ofthese is used as the lithium compound.

Advantageous Effects of the Invention

By using the positive electrode active material for a nonaqueouselectrolyte secondary battery of the present invention, a nonaqueouselectrolyte secondary battery having high charging and dischargingcapacities as well as an excellent cycle characteristic can be obtained.In addition, the production method of the positive electrode activematerial can be easily carried out even in an industrial scale, so thatan industrial value thereof is very high.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic diagram illustrating one example of the positiveelectrode active material for a nonaqueous electrolyte secondary batteryaccording to the present embodiment.

FIG. 1B is a diagram explaining the area inside the positive electrodeactive material for a nonaqueous electrolyte secondary battery.

FIG. 2 is a flow diagram (rough diagram) illustrating one example of themethod for producing the positive electrode active material for anonaqueous electrolyte secondary battery according to the presentembodiment.

FIG. 3 is a flow diagram illustrating one example of the crystallizationprocess in the method for producing the positive electrode activematerial for a nonaqueous electrolyte secondary battery according to thepresent embodiment.

FIG. 4 is a schematic cross-sectional view of a coin-type battery usedfor evaluation of the battery characteristics.

FIG. 5 is a SEM picture of a cross section of the positive electrodeactive material of Example 1.

FIG. 6 is a SEM picture of a cross section of the positive electrodeactive material of Comparative Example 4.

DESCRIPTION OF EMBODIMENTS

Hereinafter, one example with regard to each of the positive electrodeactive material for a nonaqueous electrolyte secondary battery, theproduction method thereof, and so forth according to the presentembodiment will be explained with referring to the drawings. It shouldbe note that in order to promote understanding of each component moreeasily, the drawings are expressed while emphasizing or omitting someparts thereof; and thus, the structure, shape, drawing scale, or thelike may be different from those of the actual ones. In addition, thepresent embodiment to be explained hereinafter does not intend toincorrectly limit the content of the present invention described in theclaims; and all of the components explained in the present invention arenot necessarily essential as the means to solve the present invention.

(1) Positive Electrode Active Material for a Nonaqueous ElectrolyteSecondary Battery

FIG. 1A is a schematic diagram illustrating one example of thelithium-metal composite oxide 11 that constitutes the positive electrodeactive material 10 for a nonaqueous electrolyte secondary battery of thepresent invention (hereinafter, this is also referred to as “positiveelectrode active material 10”), and FIG. 1B is a diagram to explain thearea inside the positive electrode active material 10. As illustrated inFIG. 1A, the lithium-metal composite oxide 11 contains the secondaryparticle 13 formed of a plurality of flocculated primary particles 12.In addition, the secondary particle 13 has the void 14 among the primaryparticles 12. Furthermore, the lithium-metal composite oxide 11 mainlycontains the secondary particle 13 formed of a plurality of flocculatedprimary particles 12; however, this may include a small amount of theindependent primary particle 12 such as, for example, the primaryparticle 12 that is not flocculated as the secondary particle 13 and theprimary particle 12 that is dropped off from the secondary particle 13after being flocculated.

In the positive electrode active material 10 including the lithium-metalcomposite oxide 11 containing the secondary particle 13 formed of aplurality of flocculated primary particles 12, the particle structurethereof, especially the void ratio thereof, has a significant effect tothe characteristics of the nonaqueous electrolyte secondary battery(hereinafter, this is also referred to as “secondary battery) upon usingthis material in the secondary battery. As illustrated in FIG. 1B, whenthe void ratio in the inner area that is from the central part C of thesecondary particle 13 to one half of the radius r of the secondaryparticle 13 (first area R1) was made within a specific range, and thevoid ratio in the area outside this area (second area R2) was madewithin a specific range that is lower than the void ratio in the firstarea R1, the inventors of the present invention found that upon usingthis positive electrode active material 10 in the secondary battery, aretention rate of the battery capacity upon repeat of the charging anddischarging operations (hereinafter, this retention rate is alsoreferred to as “cycle characteristic”) was able to be increased withoutdecreasing the charging and discharging capacities of the secondarybattery (hereinafter, this is also referred to as “battery capacity”).On the basis of this finding, the present invention has been completed.The reason why the cycle characteristic can be improved is notparticularly limited; however, it is presumed that, for example, whenthe positive electrode active materials having different void ratios ineach area of the secondary particle 13 are used, cracking of thesecondary particle 13 upon repeat of the charging and dischargingoperations can be suppressed thereby leading to a decrease indeterioration of the battery capacity due to the cracking of thesecondary particle 13.

In the positive electrode active material 10, the void ratio in thefirst area R1 (hereinafter, this is also referred to as “inner area R1”)is at least 5.0% and up to 50%. Here, the inner area R1 is the area fromthe central part C of the cross section of the secondary particle 13 toone half of the radius r of the secondary particle 13; and thus, forexample, when the center of gravity of the cross sectional shape formedof the outer circumference of the secondary particle 13 is regarded asthe central part C and the shortest distance from the central part C toan arbitrary point on the outer circumference of the secondary particle13 is regarded as the radius r, the inner area R1 is the area from thecentral part to one half of the radius (see, FIG. 1B). When the voidratio in the inner area R1 is within the range described above, thecycle characteristic of the secondary battery using the positiveelectrode active material 10 enhances. When the void ratio in the innerarea R1 is less than 5.0%, the stress load due to expansion andshrinkage of the particle caused by charging and discharging cannot berelaxed; and thus, cracking of the secondary particle 13 upon repeat ofthe charging and discharging operation cannot be reduced, therebyresulting in deterioration of the cycle characteristic. On the otherhand, when the void ratio in the inner area R1 is more than 50%, becausethe density of the secondary particle 13 decreases, the packing densityinto a battery vessel becomes insufficient; and thus, the energy densityper battery volume is prone to decrease. In view of increasing theenergy density furthermore, the void ratio in the inner area R1 ispreferably up to 20%.

In the positive electrode active material 10, the void ratio in thesecond area R2 (hereinafter, this is also referred to as “outer areaR2”) is up to 1.5%. Here, the outer area R2 is the area outside theinner area R1 in the secondary particle 13, namely the whole area otherthan the inner area R1 in the secondary particle 13 (see, FIG. 1B). Whenthe void ratio of the outer area R2 is within the range described above,the density of the secondary particle 13 is increased so that the energydensity is increased, and the strength of the secondary particle 13 isenhanced so that the cracking of the secondary particle 13 issuppressed. In view of increasing the energy density furthermore, thevoid ratio in the outer area R2 is preferably up to 1.0%. Here, thelower limit of the void ratio in the outer area R2 is, for example, atleast 0.05%, and preferably at least 0.1%.

When the void ratios of the inner area R1 and of the outer area R2 arebrought into within the respective ranges as described above, thepositive electrode active material 10 can have a high energy density,and also can efficiently relax the stress load caused by expansion andshrinkage upon charging and discharging. Therefore, the secondarybattery using this material can have a high battery capacity as well asan excellent cycle characteristic.

Here, the void ratios inside the positive electrode active material 10(inner area R1 and outer area R2) can be obtained by analyzing thepicture (SEM picture) that is obtained by a scanning electron microscope(SEM). For example, the positive electrode active material 10 (secondaryparticle 13) is buried into a resin or the like, and then, the SEMpicture is taken under the state capable of observing the cross sectionof the secondary particle 13 after it is subjected to a cross sectionpolisher treatment or the like; and next, by using an image analysissoftware such as WinRoof 6.1.1 (trade name), the void is detected as ablack portion, and thus, the void ratio can be obtained as the valueexpressed with [(area of void 14 in each area of the secondary particle13/cross section area in each area of the secondary particle13)×100](%). For example, in the case of the void ratio in the innerarea R1, the void ratio thereof can be obtained from [(area of void 14in the inner area R1/cross section area in the inner area R1)×100](%),namely [(area of void 14 in the inner area R1/sum of the cross sectionarea of the primary particle 12 and the void 14 in the inner areaR1)×100](%).

Here, the cross section of the secondary particle 13 to be observed isobtained from 20 secondary particles 13 selected arbitrarily (randomly)as follows. Namely, the selection is made such that in the cross sectionof a plurality of secondary particles 13, the maximum distance d betweentwo points on the outer circumference of the cross section of onesecondary particle 13 (see, FIG. 1A) is at least 80% of thevolume-average particle diameter (MV) measured using a laser diffractionscattering particle size analyzer.

In the positive electrode active material 10, the tap density ispreferably at least 2.0 g/cm³ and up to 2.6 g/cm³, while more preferablyat least 2.1 g/cm³ and up to 2.5 g/cm³. When the tap density is withinthe range described above, the positive electrode active material 10 canbe competitive in excellent battery capacity and fillability, and thus,the energy density of the secondary battery can be increasedfurthermore.

In addition, in the positive electrode active material 10, thevolume-average particle diameter MV is preferably at least 5 μm and upto 20 μm, while more preferably at least 6 μm and up to 15 μm. Withthis, the decrease in the specific surface area can be suppressed whileretaining the fillability high; and thus, the secondary battery usingthis positive electrode active material 10 can be competitive in highpacking density and excellent output characteristic.

In addition, in the positive electrode active material 10,[(D90−D10)/average particle diameter] that is an indicator to representa spread of the particle size distribution thereof, is preferably atleast 0.70. When the indicator to represent a spread of the particlesize distribution of the nickel-manganese composite hydroxide is withinthe range described above, fine particles and coarse particles are mixedin a suitable degree; and thus, the fillability of the particle can beenhanced while suppressing deterioration of the cycle characteristic andthe output characteristic of the positive electrode active material tobe obtained. In view of suppressing excessive mixing of the fineparticles or the coarse particles into the positive electrode activematerial, the indicator to represent a spread of the particle sizedistribution of the nickel-manganese composite hydroxide is preferablyup to 1.2, and more preferably up to 1.0.

In the [(D90−D10)/average particle diameter], D10 means the particlediameter at which the cumulative volume reaches 10% of the total volumeof the entire particles, the cumulative volume being obtained byaccumulating the particle number in each particle diameter from a sideof the small particle diameter; and D90 means the particle diameter atwhich the cumulative volume reaches 90% of the total volume of theentire particles, the cumulative volume being obtained by similarlyaccumulating the particle number. The average particle diameter is thevolume-average particle diameter MV, which means the volume-weightedaverage particle diameter. The volume-average particle diameter MV, D90,and D10 can be measured by using a laser diffraction scattering particlesize analyzer.

The lithium-metal composite oxide 11 is represented by the generalformula: Li_(a)Ni_(x)Co_(y)Mn_(z)M_(t)O_(2+α) (0.95≤a≤1.50, 0.30≤x≤0.70,0.10≤y≤0.35, 0.20≤z≤0.40, 0≤t≤0.1, x+y+z+t=1, and 0≤α≤0.5; and M is atleast one element selected from Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, Fe, andW). The lithium-metal composite oxide 11 having the above compositionformula has the crystal structure of a layered rock salt structure.Here, the Greek letter a in the general formula is a coefficient thatchanges with the ratio of the number of Li atoms to the metal elementsother than Li included in the lithium-metal composite oxide 11 and withthe valencies of the metal elements other than Li.

In the general formula, the alphabetical character x, which indicatesthe content of nickel, is 0.30≤x≤0.70, while preferably 0.30≤x≤0.60.Namely, the lithium-metal composite oxide 11 includes nickel as themetal element, in which the content of nickel relative to the total ofthe metal elements other than lithium is at least 30 atom % and up to 70atom %, while preferably at least 30 atom % and up to 60 atom %. Whenthe lithium-metal composite oxide 11 has the crystal structure of thelayered rock salt structure and the nickel content therein is within therange described above, this can realize a high battery capacity when itis used in the secondary battery.

In the general formula, the alphabetical character y, which indicatesthe content of cobalt, is 0.10≤y≤0.35, while preferably 0.15≤y≤0.35.Namely, the content of cobalt relative to the total of the metalelements other than lithium is at least 10 atom % and up to 35 atom %,while preferably at least 15 atom % and up to 35 atom %. When the cobaltcontent therein is within the range described above, a highly stablecrystal structure can be obtained so that an excellent cyclecharacteristic can be obtained.

In the general formula, the alphabetical character z, which indicatesthe content of manganese, is 0.20≤z≤0.40. Namely, the content ofmanganese relative to the total of the metal elements other than lithiumis at least 20 atom % and up to 40 atom %. When the manganese contenttherein is within the range described above, a high heat stability canbe obtained. When the lithium-metal composite oxide 11 according to thepresent embodiment has the specific void ratio as mentioned above andcontains nickel, cobalt, and manganese, not only further enhancedbattery capacity and heat stability can be ensured but also a very goodcycle characteristic can be obtained.

(2) Method for Producing the Positive Electrode Active Material for aNonaqueous Electrolyte Secondary Battery

FIG. 2 is a flow diagram (rough diagram) illustrating one example of themethod for producing the positive electrode active material for anonaqueous electrolyte secondary battery according to one embodiment ofthe present invention (hereinafter, this material is also referred to as“positive electrode active material”); and FIG. 3 is a diagramillustrating one example of the crystallization process. With theproduction method of the positive electrode active material of thepresent embodiment, the positive electrode active material 10 includingthe lithium-metal composite oxide 11 represented by the general formula:Li_(a)Ni_(x)Co_(y)Mn_(z)M_(t)O_(2+α) (0.95≤a≤1.50, 0.30≤x≤0.70,0.10≤y≤0.35, 0.20≤z≤0.40, 0≤t≤0.1, x+y+z+t=1, and 0≤α≤0.5; and M is atleast one element selected from Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, Fe, andW) and containing the secondary particle 13 formed of a plurality offlocculated primary particles 12 can be conveniently produced in anindustrial scale.

The production method of the positive electrode active material of thepresent embodiment has the crystallization process S11 and the firingprocess S12, as illustrated in FIG. 2. Hereinafter, each process will beexplained in detail. When explaining FIG. 2 and FIG. 3, FIGS. 1A and 1B,which is a schematic diagram illustrating one example of the positiveelectrode active material, will be referred as appropriate.

[Crystallization Process]

The crystallization process S11 is a process of crystallizing thenickel-cobalt-manganese composite hydroxide (hereinafter, this is alsoreferred to as “composite hydroxide”) by neutralizing a salt containingat least nickel, a salt containing at least cobalt, and a saltcontaining at least manganese in an aqueous reaction solution. In thecrystallization process S11, as illustrated in FIG. 3, an atmosphereabove a solution surface of the aqueous reaction solution, a temperatureof the aqueous reaction solution, the pH value of the aqueous reactionsolution based on the solution temperature of 25° C., and a dissolvednickel concentration in the aqueous reaction solution are controlledwithin respective specific ranges.

The inventors of the present invention carried out an extensiveinvestigation about the production condition of the composite hydroxideto be used as a precursor to the positive electrode active material 10;and as a result, it was found that: 1) in the crystallization processS11, the morphology of the composite hydroxide can be preciselycontrolled by controlling, in addition to the oxygen concentration in anatmosphere above a solution surface of the aqueous reaction solution(hereinafter, this is also referred to as “atmospheric oxygenconcentration”), the dissolved nickel concentration in the aqueousreaction solution and the pH value of the aqueous reaction solution(based on the solution temperature of 25° C.); and 2) because thepositive electrode active material 10 finally obtained is stronglyinfluenced by the morphology of the composite hydroxide, the morphologyof the positive electrode active material can be optimized by preciselycontrolling the morphology of the composite hydroxide particle. Here,“morphology” is the character relating to the form and structure of theprimary particle and/or secondary particle (composite hydroxide and/orlithium-metal composite oxide 11); here, the character includes theshape, the void ratio, the average particle diameter, the particle sizedistribution, the tap density, and the like of the particle. Namely, inthe production method of the present embodiment, controls of thedissolved nickel concentration in the aqueous reaction solution and ofthe oxygen concentration in an atmosphere above the solution surface(atmospheric oxygen concentration) are important in the crystallizationprocess S11; and by controlling these factors (parameters), the particlediameter of the secondary particle 13 and the void ratio inside thesecondary particle 13 of the positive electrode active material 10 to befinally obtained can be controlled within the respective specificranges. Hereinafter, these respective conditions in the crystallizationprocess S11 will be explained.

(Oxygen Concentration)

The atmospheric oxygen concentration is appropriately controlled in therange of at least 0.2% by volume and up to 2% by volume. When theatmospheric oxygen concentration is controlled within the range asdescribed above, the morphologies of the primary particle and thesecondary particle of the composite hydroxide can be controlled so thatthe lithium-metal composite oxide 11 having suitable void ratios as thepositive electrode active material 10 can be obtained. For example, whenthe atmospheric oxygen concentration is controlled within theabove-mentioned range, the void ratio in the outer area R2 of thepositive electrode active material 10 can be increased within theafore-mentioned range in response to increase in the atmospheric oxygenconcentration. Namely, the atmospheric oxygen concentration can have apositive relation with the void ratio in the outer area R2; and thus, onthe basis of this relation, the void ratio in the outer area R2 can becontrolled within the afore-mentioned range.

When the atmospheric oxygen concentration is less than 0.2% by volume,oxidation of transition metals, especially oxidation of manganese hardlytakes place; and as a result, inside the secondary particle of thecomposite hydroxide becomes extremely dense. In addition, itoccasionally shows a peculiar shape in the surface thereof. In thepositive electrode active material obtained using the compositehydroxide like this, the void ratios of the inner area R1 and of theouter area R2 in the secondary particle are decreased, thereby leadingto deterioration of the cycle characteristic as well as increase in thereaction resistance resulting in deterioration of the outputcharacteristic. On the other hand, when the atmospheric oxygenconcentration is more than 2% by volume, the secondary particle of theformed composite hydroxide becomes sparse so that the void ratios areincreased, and as a result, the void ratio in the outer area R2 of thesecondary particle of the positive electrode active material increasesthereby leading to deterioration of the cycle characteristic. Theatmospheric oxygen concentration can be controlled by introducing gasessuch as an inert gas (for example, N₂ gas and Ar gas), an air, or oxygeninto a space inside the reaction vessel while controlling the flow ratesof these gases or the composition of the gases. Here, these types ofgases may be blown into the aqueous reaction solution as well.

(Dissolved Nickel Concentration)

The dissolved nickel concentration in the aqueous reaction solution iscontrolled in the range of at least 300 mg/L and up to 900 mg/L, whilepreferably in the range of at least 300 mg/L and up to 850 mg/L, basedon the temperature of the aqueous reaction solution. When the dissolvenickel concentration is appropriately controlled within the range asdescribed above, the particle diameter and particle structure of thepositive electrode active material can be controlled by controlling theparticle diameter and void ratios of the composite hydroxide. Forexample, when the dissolved nickel concentration is controlled withinthe above-mentioned range, in response to the increase in the dissolvednickel concentration, the void ratio in the inner area R1 of thepositive electrode active material 10 can be increased within theafore-mentioned range. Namely, the dissolved nickel concentration canhave a positive relation with the void ratio in the inner area R1; andthus, on the basis of this relation, the void ratio in the inner area R1can be controlled within the afore-mentioned range.

When the dissolved nickel concentration in the aqueous reaction solutionis less than 300 mg/L, the growth rate of the primary particle of thecomposite hydroxide is so fast that the nucleation becomes dominant overthe particle growth thereby leading to decrease in the size of theprimary particle; and thus, this occasionally causes poor sphericity inthe secondary particle. When the composite hydroxide like this is firedafter it is mixed with lithium, whole of the secondary particle shrinksso that the void ratio in the inner area R1 of the secondary particledecreases. In addition, because of the poor sphericity of the positiveelectrode active material, a high energy density cannot be obtained whenthis is used in the battery. On the other hand, when the dissolvednickel concentration is more than 900 mg/L, a generation rate of thesecondary particle of the composite hydroxide becomes so slow that thisoccasionally causes a decrease in the void ratios of the positiveelectrode active material 10. In addition, occasionally nickel remainsin the filtrate thereby causing significant deviation of the compositionof the obtained composite hydroxide from the target values thereof.Besides, under the condition of excessively high dissolved nickelconcentration, impurities included in the composite hydroxide increasesso much that this occasionally causes deterioration of the batterycharacteristics when the positive electrode active material(lithium-metal composite oxide 11) obtained from the composite hydroxideis used in the battery.

(pH Value)

The pH value of the aqueous reaction solution is in the range of atleast 11.0 and up to 12.5, preferably in the range of at least 11.0 andup to 12.3, while more preferably in the range of at least 11.0 and upto 12.0, based on the solution temperature of 25° C. When the pH valueis within the range described above, the size and shape of the primaryparticle of the composite hydroxide can be controlled so as to controlthe void ratios of the secondary particle; and thus, the morphology ofthe secondary particle can be properly controlled. Accordingly, thelithium-metal composite oxide 11 that is further suitable as thepositive electrode active material 10 can be obtained.

When the pH value is less than 11.0, the generation rate of thecomposite hydroxide becomes extremely slow so that coarse secondaryparticles are formed. In addition, occasionally nickel remains in thefiltrate thereby causing significant deviation of the composition of theobtained composite hydroxide from the target values thereof. On theother hand, when the pH value is more than 12.5, the particle growthrate is so fast that nucleation can readily takes place thereby leadingto the particle with a small particle diameter and a poor sphericity, sothat this occasionally causes deterioration of the fillability of thepositive electrode active material.

(Reaction Temperature)

The temperature of the aqueous reaction solution in the crystallizationreaction vessel is preferably in the range of at least 38° C. and up to45° C. It is also preferable to control the upper and lower limits ofthe temperature within 5° C. By so doing, the particle growth of thecomposite hydroxide can be stabilized, so that the shapes and particlediameters of the primary and secondary particles can be readilycontrolled.

When the temperature of the aqueous reaction solution is higher than 45°C., priority of the nucleation relative to the particle growth in theaqueous reaction solution rises, so that the shape of the primaryparticle that constitutes the composite hydroxide is prone to be toofine. On the other hand, when the temperature of the aqueous reactionsolution is lower than 38° C., there is a tendency that the particlegrowth is dominant over the nucleation; and thus, the shapes of theprimary and secondary particles that constitute the composite hydroxideare prone to be coarse. When the composite hydroxide having the coarsesecondary particle like this is used as the precursor to the positiveelectrode active material, there is a problem of forming the positiveelectrode active material containing particles that are so large andcoarse thereby likely to generate irregularity in the electrode uponproduction thereof. In addition, when the temperature of the aqueousreaction solution is lower than 35° C., there is a problem of a verypoor reaction efficiency because remaining amounts of the metal ions inthe aqueous reaction solution are so high; and moreover, the problem isprone to appear that the composite hydroxide including large amounts ofimpurity elements is formed.

(Others)

The production method of the present embodiment includes thecrystallization process S11 in which the nickel-cobalt-manganesecomposite hydroxide particle is formed by neutralizing the saltsincluding at least nickel, cobalt, and manganese in the aqueous reactionsolution. In the specific embodiment of the crystallization process, forexample, the pH value is controlled by neutralization. Here, aneutralizing agent (for example, an alkaline solution) is added to amixed aqueous solution including at least nickel (Ni), cobalt (Co), andmanganese (Mn) in the reaction vessel while stirring the mixed aqueoussolution at a constant stirring rate, and thereby the compositehydroxide particle can be formed by co-precipitation.

In the crystallization process S11, the stirring power to be applied tothe aqueous reaction solution is not particularly limited so far as thepositive electrode active material 10 as described above can beproduced; and thus, the stirring power is controlled preferably in therange of at least 2.0 kW/m³ and up to 6.7 kW/m³, while more preferablyin the range of at least 3 kW/m³ and up to 6.5 kW/m³. When the stirringpower within the range as described above is applied, formation ofexcessively fine or coarse secondary particles can be suppressed, sothat the particle diameter of the composite hydroxide can be madefurther suitable as the positive electrode active material.

In the production method of the present embodiment, any of acrystallization method based on a batch system and a continuouscrystallization method may be employed. Here, the continuouscrystallization method is a process in which while continuously feedingthe mixed aqueous solution as described above, pH is controlled byfeeding the neutralizing agent, and whereby the composite hydroxideparticles thus formed is recovered by overflowing. For example, in thecrystallization process, the mixed aqueous solution including nickel,cobalt, and manganese is continuously added to the reaction vessel, andthen, slurry including the composite hydroxide particles formed byneutralization is overflowed so that the particles can be recovered. Inthe continuous crystallization method, the particles having a broaderparticle size distribution as compared with the batch method, forexample, the particles having [(D90−D10)/average particle diameter] thatis an indicator to represent a spread of the particle size distributionthereof at least 0.7 can be obtained; thus, the particles having a highfillability are prone to be obtained. In addition, the continuouscrystallization method is suitable for mass production, so that this isalso an industrially advantageous production method. For example, whenproduction of the composite hydroxide of the present embodiment iscarried out by the continuous crystallization method, the fillability(tap density) of the composite hydroxide particles to be obtained can beimproved furthermore, so that the composite hydroxide having furtherimproved fillability and void ratios can be produced conveniently andmassively.

With regard to the mixed aqueous solution, an aqueous solution includingat least nickel, cobalt, and manganese, namely, an aqueous solutionhaving at least a nickel salt, a cobalt salt, and a manganese saltdissolved therein may be used. In addition, the mixed aqueous solutionmay include M; and thus, an aqueous solution having a nickel salt, amanganese salt, and an M-including salt dissolved therein may be used.With regard to the nickel salt, the manganese salt, and the M-includingsalt, for example, at least one selected from the group consisting ofsulfate, nitrate, and chloride may be used. Among them, in view of acost as well as a waste water treatment, sulfate salts thereof arepreferably used.

Concentration of the mixed aqueous solution is preferably in the rangeof at least 1.0 mol/L and up to 2.5 mol/L, while more preferably in therange of at least 1.5 mol/L and up to 2.5 mol/L, as a total of the metalsalts dissolved therein. With this, the particle diameter of thecomposite hydroxide can be readily controlled in a proper size, so thatthe fillability of the positive electrode active material to be obtainedcan be improved. Here, the composition of the metal elements included inthe mixed aqueous solution coincides with the composition of the metalelements included in the composite hydroxide to be obtained.Accordingly, the composition of the metal elements in the mixed aqueoussolution can be adjusted so as to be the same as the composition of themetal elements of the target composite hydroxide.

Together with the neutralizing agent, a complexing agent may also beadded into the mixed aqueous solution. The complexing agent is notparticularly limited so far as it can form a complex in an aqueoussolution by bonding to metal elements such as a nickel ion, a cobaltion, and a manganese ion. For example, as the complexing agent, anammonium-ion-providing body may be cited. The ammonium-ion-providingbody is not particularly limited; for example, at least one solutionselected from the group consisting of an aqueous ammonium solution, anaqueous ammonium sulfate solution, and an aqueous ammonium chloridesolution may be used. Among theme, in view of easy handling, the aqueousammonium solution is preferably used. In the case when theammonium-ion-providing body is used, the ammonium ion concentration ispreferably made in the range of at least 5 g/L and up to 25 g/L, whilemore preferably in the range of at least 5 g/L and up to 15 g/L. By sodoing, fluctuation of the particle diameter due to fluctuation of the pHvalue can be suppressed, so that the particle diameter can be controlledmore readily. In addition, the sphericity of the composite hydroxide canbe improved furthermore, so that the fillability of the positiveelectrode active material can be improved.

With regard to the neutralizing agent, an alkaline solution may be used;for example, an aqueous solution of a general alkali metal hydroxidesuch as sodium hydroxide or potassium hydroxide may be used. Among them,in view of a cost and a handling easiness, the sodium hydroxide aqueoussolution is preferably used. Here, the alkali metal hydroxide may beadded directly into the aqueous reaction solution; however, in view ofeasy control of pH, it is added preferably as the aqueous solutionthereof. In this case, concentration of the alkali metal hydroxideaqueous solution is preferably in the range of at least 12% by mass andup to 30% by mass, while more preferably in the range of at least 20% bymass and up to 30% by mass. When concentration of the alkali metalhydroxide aqueous solution is less than 12% by mass, the supply amountthereof to the reaction vessel is increased, so that there is a risk ofinsufficient particle growth. On the other hand, when concentration ofthe alkali metal hydroxide aqueous solution is more than 30% by mass,the pH value becomes locally high depending on the addition position ofthe alkali metal hydroxide, so that there is a risk of forming fineparticles.

After the crystallization process S11, it is preferable to wash thecomposite hydroxide. This washing process is a process in which theimpurities included in the composite hydroxide obtained in thecrystallization process S11 is washed out. It is preferable to usepurified water as the washing solution. The amount of the washingsolution is preferably at least 1 L relative to 300 g of the compositehydroxide. When the amount of the washing solution relative to 300 g ofthe composite hydroxide is less than 1 L, washing thereof isinsufficient, so that occasionally the impurities are left in thecomposite hydroxide. The washing may be carried out by pouring thewashing solution such as purified water to a filtration machine such as,for example, a filter press. In the case when SO₄ that is left in thecomposite oxide needs to be washed out furthermore, it is preferable touse sodium hydroxide or sodium carbonate as the washing solution.

After washing, drying is carried out preferably in the temperature rangeof at least 110° C. and up to 150° C. The drying temperature and timemay be set approximately in such a level that the moisture includedtherein can be removed; for example, the time is in the range of atleast about 1 hour and up to about 24 hours. In addition, a heattreatment process may be further added in which the composite hydroxideafter being dried is heated in the temperature range of at least 350° C.and up to 800° C. so as to convert it to the nickel-cobalt-manganesecomposite oxide (hereinafter, this is also referred to as “compositeoxide”). With this heat treatment, generation of a water vapor issuppressed in the firing process S12, which follows thereafter, so thatnot only the reaction with a lithium compound can be facilitated butalso the ratio of the metal elements other than lithium to lithium inthe positive electrode active material 10 can be stabilized. When theheat treatment temperature in the heat treatment process is lower than350° C., conversion to the composite oxide is insufficient. On the otherhand, when the heat treatment temperature is higher than 800° C.,sintering among the composite oxide particles themselves canoccasionally take place thereby generating coarse particles. Besides,because much energy is needed, such a high temperature heat treatment isindustrially unsuitable. The atmosphere of the heat treatment is notparticularly limited, and a non-reducing atmosphere that includes oxygenmay be used. The heat treatment is carried out preferably in an airatmosphere in view of convenience.

The heat treatment time is set such that conversion to the compositeoxide may be sufficient; therefore, it is preferably the range of 1 to10 hours. The equipment to be used in the heat treatment is notparticularly limited; and thus, the equipment with which the compositehydroxide can be heated in a non-reducing atmosphere that includesoxygen, preferably in an air atmosphere, may be used. For this, theequipment not generating a gas, such as, for example, an electricfurnace or the like is suitably used.

[Firing Process]

The firing process S12 is a process of firing the mixture obtained bymixing the composite hydroxide with a lithium compound in an oxygenatmosphere to obtain the lithium-metal composite oxide. The compositehydroxide or the composite oxide obtained by heat treatment of thehydroxide is mixed with the lithium compound such that the ratio (Li/Me)of the number of the lithium atom (Li) to the total number of the atomsof the metal elements other than lithium (Me) will be at least 0.95 andup to 1.50, preferably at least 0.98 and up to 1.15, while morepreferably at least 1.01 and up to 1.09. Namely, because the ratio Li/Medoes not change before and after the firing process, the mixing ratio ofLi/Me in the mixing process is the Li/Me ratio in the positive electrodeactive material; and thus, the mixing is carried out such that the ratioLi/Me in the mixture may be the same as the Li/Me ratio in the positiveelectrode active material to be obtained.

When the composite hydroxide (composite oxide) and the lithium compoundare mixed such that the Li/Me ratio falls within the range as describedabove, crystallization is facilitated. When the Li/Me ratio is less than0.95, part of the oxide does not react with lithium thereby leaving thelithium unreacted so that occasionally a sufficient battery performancecannot be obtained. On the other hand, when the Li/Me ratio is more than1.50, sintering is facilitated thereby leading to an increase in theparticle diameter and the crystallite diameter so that occasionally asufficient battery performance cannot be obtained.

The lithium compound to be used for forming the lithium mixture is notparticularly limited; however, in view of easy availability, forexample, lithium hydroxide, lithium nitrate, lithium carbonate, or amixture of these are preferable. In particular, considering the handlingeasiness and quality stability thereof, lithium hydroxide, lithiumcarbonate, or a mixture of these is more preferably used.

Here, it is preferable that the lithium mixture be fully mixed beforebeing fired. When the mixing is not sufficient, the Li/Me ratiofluctuates among particles, so that there are possibilities ofinsufficient battery characteristics and the like; and thus, they needto be fully mixed before being fired. For mixing, general mixingmachines may be used, such as, for example, a shaker mixer, a Lodigemixer, a Julia mixer, and a V blender so far as the composite oxideparticles can be sufficiently mixed with the lithium-containingsubstance to a degree that the shape and structure of the heat-treatedparticles and the like are not destroyed.

Next, the mixture is fired in an oxygen atmosphere, i.e., in anoxygen-containing atmosphere, to obtain the lithium-metal compositeoxide. The firing temperature at this time is made preferably at least800° C. and up to 1000° C. With this, the crystallinity thereof isenhanced and the displacement is facilitated. When the firingtemperature is lower than 800° C., the lithium raw material cannot fullyreact, so that excess lithium is left, or the crystal cannot be grownsufficiently well thereby occasionally causing deterioration of thebattery characteristics. On the other hand, when the firing temperatureis higher than 1000° C., sintering and flocculation advance therebyoccasionally leading to deterioration of the fillability of theparticles and the battery characteristics. In addition, mixing betweenthe Li site and the transition metal site can take place thereby leadingto deterioration of the battery characteristics.

The firing time is not particularly limited, and it is in the range ofat least about 1 hour and up to about 24 hours. When the firing time isless than 1 hour, the lithium raw material cannot react fully, so thatoccasionally excess lithium is left, or the crystal cannot be grownsufficiently well thereby leading to deterioration of the batterycharacteristics. In view of uniformly carrying out the reaction betweenthe lithium compound and the composite hydroxide or the composite oxideobtained by oxidizing the composite hydroxide, the temperature raisingrate is preferably, for example, in the range of at least 1° C./minuteand up to 10° C./minute until the firing temperature. In addition,before being fired, the mixture may be kept at the temperature aroundthe melting point of the lithium compound for a period of about 1 hourto about 10 hours. By so doing, the reaction can be carried out furtheruniformly.

Here, the furnace to be used in firing is not particularly limited, sothat any furnace may be used so far as the mixture can be heated in anair atmosphere or in an oxygen stream; however, in view of keeping theatmosphere inside the furnace uniformly, an electric furnace notgenerating a gas is preferable. Here, any of a batch system and acontinuous system may be used.

Occasionally, the lithium-metal composite oxide obtained by firing isflocculated or lightly sintered. In this case, the oxide may be crushed;and by so doing, the lithium-metal composite oxide 11, namely, thepositive electrode active material 10 according to the presentembodiment can be obtained. Here, the term “crushing” means theoperation in which a mechanical energy is applied to the flocculateformed of a plurality of secondary particles thereby loosening theflocculate so as to separate the secondary particles withoutsignificantly destroying the secondary particle itself, the flocculatebeing formed by sintering necking or the like among the secondaryparticles during firing.

(3) Nonaqueous Electrolyte Secondary Battery

The nonaqueous electrolyte secondary battery (hereinafter, this is alsoreferred to as “secondary battery”) of the present embodiment includes apositive electrode, a negative electrode, and a nonaqueous electrolytesolution, and composed of the same composition elements as those of ageneral lithium ion secondary battery. Hereinafter, one example of thesecondary battery of the present embodiment will be explained withrespect to each composition element separately. It should be noted thatthe embodiments explained hereinafter are mere examples, so that thesecondary battery may be carried out not only with the embodimentsdescribed below but with the embodiments changed or modified variouslyon the basis of a knowledge of a person ordinarily skilled in the art.In addition, the secondary battery is not particularly limited in theuse thereof.

(Positive Electrode)

The positive electrode of the nonaqueous electrolyte secondary batteryis prepared by using the positive electrode active material 10 asdescribed above. Hereinafter, one example of the production method ofthe positive electrode will be explained. First, the positive electrodeactive material 10 (powder form), a conductive agent, and a binder aremixed, and as needed, an activated carbon and a solvent for the purposeof viscosity adjustment and the like are added thereto; and then, theyare kneaded to prepare a positive electrode mixed material paste.

The mixing ratios of each material in the positive electrode mixedmaterial serve as a factor to determine the performance of the lithiumsecondary battery; and thus, the ratios can be adjusted in accordancewith the use thereof. The mixing ratios of the materials may be made assame as those of publicly known positive electrodes of the lithiumsecondary battery; therefore, for example, when total mass of the solidportions in the positive electrode mixed material excluding the solventis regarded as 100% by mass, the positive electrode active material maybe included therein in the range of 60% by mass to 95% by mass, theconductive agent in the range of 1% by mass to 20% by mass, and thebinder in the range of 1% by mass to 20% by mass.

The positive electrode mixed material paste thus obtained is applied tothe surface of an electric collector made of, for example, aluminumfoil, and then it is dried to scatter the solvent to prepare thesheet-like positive electrode. As needed, in order to increase theelectrode density, it is also pressed with a roll-press or the like. Thesheet-like positive electrode obtained in the way as described above is,for example, cut to a proper size in accordance with the target battery;and then, this can be used for fabrication of the battery. However, thepreparation method of the positive electrode is not limited to theabove-mentioned example, so that it may also be prepared by othermethods.

With regard to the conductive agent, for example, graphite (such asnatural graphite, artificial graphite, and expandable graphite) as wellas carbon black materials such as acetylene black and Ketchen black maybe used.

The binder plays a role to bind the active material particles; here, forexample, polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE),a fluorine rubber, an ethylene propylene diene rubber, styrenebutadiene, a cellulose-based resin, and polyacrylic acid may be used.

As needed, a solvent that can disperse the positive electrode activematerial, the conductive agent, and an activated carbon, and that candissolve the binder, is added to the positive electrode mixed material.With regard to the solvent, an organic solvent specifically such asN-methyl-2-pyrrolidone may be used. In addition, in order to increasethe electric double layer capacity, an activated carbon may be added tothe positive electrode mixed material.

(Negative Electrode)

As the negative electrode, a metal lithium, a lithium alloy, or the likemay be used. Alternatively, a shaped article may be used as the negativeelectrode, the article being prepared in such a way that a negativeelectrode mixed material, which is prepared by mixing a binder with anegative electrode active material capable of inserting and de-insertinga lithium ion followed by addition of a suitable solvent so as to makeit a paste-like form, is applied to the surface of an electric collectormade of metal foil such as copper foil, and then, it is dried and, asneeded, compressed so as to increase the electrode density.

With regard to the negative electrode active material, for example,natural graphite, artificial graphite, a fired body of an organiccompound such as a phenol resin, or a powdery body of a carbon substancesuch as cokes may be used. In this case, similarly to the positiveelectrode, among others a fluorine-containing resin such as PVDF may beused as the negative electrode binder; and as the solvent to dispersethe active material and the binder, an organic solvent such asN-methyl-2-pyrrolidone may be used.

(Separator)

Between the positive electrode and the negative electrode, a separatoris interposed, and then it is disposed. The separator separates betweenthe positive electrode and the negative electrode, and it also storesthe electrolyte; for example, a thin film that is made of polyethylene,polypropylene or the like and has many fine pores may be used.

(Nonaqueous Electrolyte Solution)

The nonaqueous electrolyte solution is made by dissolving a lithium saltas a supporting salt in an organic solvent. Illustrative example of theorganic solvent includes cyclic carbonates such as ethylene carbonate,propylene carbonate, butylene carbonate, and trifluoropropylenecarbonate; linear carbonates such as diethyl carbonate, dimethylcarbonate, ethyl methyl carbonate, and dipropyl carbonate; ethercompounds such as tetrahydrofuran, 2-methyl tetrahydrofuran, anddimethoxy ethane; sulfur compounds such as ethyl methyl sulfone andbutane sultone; and phosphorous compounds such as triethyl phosphate andtrioctyl phosphate; here, a single solvent selected from these solventsor a mixture of two or more of them may be used.

With regard to the supporting salt, LiPF₆, LiBF₄, LiClO₄, LiAsF₆,LiN(CF₃SO₂)₂, composite salts of them, or the like may be used.Furthermore, the nonaqueous electrolyte solution may include a radicalscavenger, a surfactant, a flame retardant, and so forth.

(Form and Composition of the Battery)

The nonaqueous electrolyte secondary battery of the present invention,which as explained above includes the positive electrode, the negativeelectrode, the separator, and the nonaqueous electrolyte solution, canhave various shapes such as a cylindrical shape and a laminate shape. Inany shape used, the positive electrode and the negative electrode arelaminated via the separator to form an electrode body; then, theelectrode body thus obtained is impregnated with the nonaqueouselectrolyte solution. Then, between a positive electrode collector and apositive electrode terminal leading to outside, and between a negativeelectrode collector and a negative electrode terminal leading to outsideare connected by a collector lead or the like; and then, they are sealedin a battery case thereby completing the nonaqueous electrolytesecondary battery.

(Characteristics)

The secondary battery according to the present embodiment has a highcapacity and an excellent heat stability. The secondary battery usingthe positive electrode active material 10 that is obtained by apreferable embodiment, for example, a 2032 coin-type battery that isproduced with the condition of Examples to be described later, can havea high initial discharging capacity of at least 165 mAh/g; and when thecomposition and production method thereof are optimized, the secondarybattery having a further enhanced capacity can be produced. In addition,for example, when the cycle characteristic is evaluated by using the2032 coin-type battery that is produced with the condition of Examplesto be described later, the ratio of the discharging capacity D₁ that isthe value after 500 repeats of the charging and discharging operationsto the initial discharging capacity D₀ ([D₁/D₀]×100) may be at least75%, or at least 77% when the condition is further optimized.

EXAMPLES

Hereinafter, the positive electrode active material for a nonaqueouselectrolyte secondary battery according to the embodiment of the presentinvention will be explained in more detail by Examples; however, thepresent invention is not limited to these Examples.

Example 1

A prescribed amount of purified water was taken into a reaction vessel(50 L); and then, with stirring, the temperature inside the vessel wasset at 42° C. At this time, a nitrogen gas was fed into the reactionvessel so as to bring the space inside the reaction vessel to anon-oxidative atmosphere (oxygen concentration: 0.3% by volume). Intothis reaction vessel were continuously and simultaneously added a 2.0mol/L mixed aqueous solution including nickel sulfate, cobalt sulfate,and manganese sulfate with the molar ratio ofnickel:cobalt:manganese=45:30:25, an alkaline solution of a 25% by massaqueous sodium hydroxide solution, and a complexing agent of a 25% bymass aqueous ammonia solution so as to make the aqueous reactionsolution thereby carrying out the neutralization crystallizationreaction. The flow rates of these solutions were controlled such thatthe residence time of the metal salts included in the mixed aqueoussolution in the reaction vessel might be 8 hours; and the pH value andthe ammonium ion concentration were controlled such that the dissolvednickel concentration in the aqueous reaction solution might be 300 mg/L(target value), and whereby the dissolved nickel concentration wasstabilized at 319 mg/L. At this time, the ammonium ion concentration inthe reaction vessel was controlled in the range of 12 to 15 g/L, wherebythe pH value of the solution based on the solution temperature of 25° C.was 12.0 with the fluctuation thereof being ±0.1. After theneutralization crystallization reaction was stabilized in the reactionvessel, the slurry including the nickel-cobalt-manganese compositehydroxide was recovered from the overflow port; and then, a cake of thenickel-cobalt-manganese composite hydroxide was obtained by suctionfiltration. Impurities included therein were washed out by pouring 1 Lof purified water to 140 g of the nickel-cobalt-manganese compositehydroxide in the suction filtration equipment that was used forfiltration (washing process). Then, the cake of thenickel-cobalt-manganese composite hydroxide after having been washed wasdried at 120° C. to obtain the nickel-cobalt-manganese compositehydroxide, i.e., the precursor to the positive electrode active material(crystallization process).

After the nickel-cobalt-manganese composite hydroxide and lithiumcarbonate were weighed so as to give the Li/Me ratio of 1.02, they werefully mixed to obtain a lithium mixture by using a shaker mixer (TURBULAType T2C; manufactured by Willy A. Bachofen AG (WAB)) while applying astrength such that the shape and structure of the precursor were stillable to be retained.

The lithium mixture was inserted into a magnesia-made firing vessel, andby using a sealed-type electric furnace, the temperature thereof wasraised in an air atmosphere with the flow rate thereof being 10 L/minuteand with the temperature raising rate of 2.77° C./minute to 900° C., atwhich temperature the mixture was kept for 10 hours; and then, it wascooled in the furnace to room temperature to obtain the positiveelectrode active material formed of the lithium-metal composite oxide(firing process).

The particle size distribution of the positive electrode active materialthus obtained was measured by using a laser diffraction scatteringparticle size analyzer. It was confirmed that the average particlediameter D50 was 7.7 μm, and [(D90−D10)/average particle diameter] was0.80. The tap density was measured by using a tapping apparatus (KYT3000; manufactured by Seishin Enterprise Co., Ltd.), and was calculatedfrom the volume and sample weight after the material was tapped for 500times. As a result, the tap density of 2.2 g/mL was obtained.

The cross section structure of the obtained positive electrode activematerial was observed by a scanning electron microscope. In FIG. 5, thecross section structure of the obtained positive electrode activematerial is displayed. In order to evaluate the void ratio, the particlecross section area of the secondary particle and the void area insidethe particle were obtained by using an image analysis software (WinRoof6.1.1 (trade name); and the respective void ratios of the inner andouter areas of the secondary particle were calculated from the equation[(void area inside the particle)/(particle cross section area)×100](%).Here, the particle cross section area was obtained as the sum of thevoid area (black portion) and the cross section of the primary particles(white portions). The center of gravity of the shape formed of the outercircumference of the secondary particle was regarded as the center ofthe secondary particle, and the shortest distance from the center to anarbitrary point on the outer circumference of the secondary particle wasregarded as the radius, and the area from the center to one half of theradius was regarded as the inner area of the secondary particle. Namely,the shape formed of the outer circumference of the secondary particleand the similar shape thereof with the similarity ratio of one half wereoverlaid while coinciding both of the center of gravity; and inside thesimilar shape was regarded as the inner area of the secondary particleand the outside the inner area was regarded as the outer area.

The void ratio of the positive electrode active material was calculatedby number-averaging the void ratios of each particle of the secondaryparticles (N=20) that were at least 80% in the volume-average particlediameter (MV). As a result, the void ratio of the inner area (firstarea) of the secondary particle was 5.2%, and that of the outer areathereof (second area) was 0.1%.

After the obtained positive electrode active material was dissolved byan inorganic acid, the chemical analysis thereof was carried out by anICP emission spectroscopy to show the composition ofLi_(1.02)Ni_(0.45)Co_(0.30) Mn_(0.25)O₂; and thus, it was confirmed thatthe particle having an intended composition was able to be obtained. Theproduction conditions and the characteristics of the obtained positiveelectrode active material are listed in Table 1.

[Fabrication of the Battery]

A mixture of 52.5 mg of the obtained positive electrode active material,15 mg of acetylene black, and 7.5 mg of polytetrafluoroethylene resin(PTFE) was press molded with the applied pressure of 100 MPa to preparethe positive electrode (electrode for evaluation) PE having the diameterof 11 mm and the thickness of 100 μm, as depicted in FIG. 4. Thepositive electrode PE thus prepared was dried at 120° C. in a vacuumdryer for 12 hours. Then, the 2032 coin-type battery CBA was prepared byusing this positive electrode PE under an Ar atmosphere in a globe boxin which the dew point was controlled at −80° C. For the negativeelectrode NE, a lithium (Li) metal having the diameter of 17 mm and thethickness of 1 mm was used. For the electrolyte solution, an equalamount mixture of ethylene carbonate (EC) and diethyl carbonate (DEC)(manufactured by Tomiyama Pure Chemical Industries, Ltd.) having 1-MLiClO₄ as the supporting electrolyte was used. For the separator SE, apolyethylene porous film having the film thickness of 25 μm was used.The coin-type battery having the gasket GA and the wave washer WW wasfabricated to the battery having a coin-like shape by using the positiveelectrode can PC and the negative electrode can NC.

The initial discharging capacity was measured as follows. Namely, afterthe open circuit voltage (OCV) was stabilized by allowing to leave thecoin-type battery for about 24 hours after it was prepared, it wascharged to the cut-off voltage of 4.3 V with the current density to thepositive electrode being 0.1 mA/cm², and after 1 hour of pause, it wasdischarged to the cut-off voltage of 3.0 V, and thereby the capacity atthis time was regarded as the initial discharging capacity.

The cycle characteristic was evaluated as follows. Namely, the cycle tocharge until 4.1 V and discharge until 3.0 V with the current density tothe positive electrode being 2 mA/cm² was repeated at 60° C. for 500times with the 2C rate; and the cycle characteristic was obtained bycalculating the ratio of the discharging capacity after the repeat ofthe charging and discharging operations to the initial dischargingcapacity. Measurement of the charging and discharging capacities wascarried out by using a multi-channel voltage/electricity generator(R6741A; manufactured by Advantest Corp.). The measurement results ofthe initial charging and discharging capacities of the obtained positiveelectrode active material and the cycle characteristic thereof arelisted in Table 1.

Examples 2 to 8

With the same conditions as Example 1 except that the atmospheric oxygenconcentration inside the reaction vessel and the dissolved nickelconcentration of the aqueous reaction solution at the time ofcrystallization were changed to those described in Table 1, the positiveelectrode active material was obtained and the evaluation thereof wascarried out. The pH values at the time of adjusting the dissolved nickelconcentration were in the range of at least 11.0 and up to 12.3 based onthe solution temperature of 25° C. The production conditions and theevaluation results are listed in Table 1.

Comparative Examples 1 to 6

With the same conditions as Example 1 except that the atmospheric oxygenconcentration inside the reaction vessel and the dissolved nickelconcentration of the aqueous reaction solution at the time ofcrystallization were changed to those described in Table 1, the positiveelectrode active material was obtained and the evaluation thereof wascarried out. The production conditions and the evaluation results arelisted in Table 1.

TABLE 1 Precipitation Lithium-metal composite process Positive electrodeactive material oxide Atmospheric Dissolved Average (D90 − D10)/ Voidratio Battery characteristics Metal element composition oxygen nickelparticle average Inner Outer Initial Li/Me concentra- concentra-diameter particle Tapped area area discharging Cycle ratio Ni Co Mn tiontion MV diameter density R1 R2 capacity characteristic a x y z (vol %)(mg/L) (μm) — (g/cm³) (%) (%) (mAh/g) (%) Example 1 1.02 0.45 0.3 0.250.3 319 7.7 0.78 2.2 5.2 0.1 169 77 Example 2 1.01 0.45 0.3 0.25 0.2 7237.6 0.81 2.4 18.9 0.1 168 78 Example 3 1.03 0.45 0.3 0.25 0.9 422 8.10.77 2.3 5.9 0.5 169 77 Example 4 1.03 0.45 0.3 0.25 1.8 322 9.2 0.762.3 5.1 0.9 168 77 Example 5 1.02 0.45 0.3 0.25 1.9 796 8.9 0.77 2.219.6 1 168 79 Example 6 1.01 0.45 0.3 0.25 1.9 398 6.3 0.76 2.1 5.5 0.9168 79 Example 7 1 0.45 0.3 0.25 1.4 772 5.5 0.73 2.1 19.2 0.7 168 79Example 8 1.01 0.45 0.3 0.25 0.8 820 8.1 0.75 2.1 22.3 0.5 166 77 Comp.1.02 0.45 0.3 0.25 0.3 240 7.7 0.75 2.1 3.2 0.1 164 72 Example 1 Comp.1.01 0.45 0.3 0.25 1.8 202 8.3 0.76 2.2 2.7 0.9 164 71 Example 2 Comp.1.01 0.45 0.3 0.25 3.1 699 8.1 0.76 2.2 17.2 1.9 161 78 Example 3 Comp.1.01 0.45 0.3 0.25 3.1 122 7.8 0.77 2.1 1.4 1.9 160 72 Example 4 Comp.1.03 0.45 0.3 0.25 5.2 110 7.9 0.75 2.2 1.2 4.8 157 71 Example 5 Comp.1.02 0.45 0.3 0.25 5.6 288 7.6 0.74 2.1 3.8 5.2 159 73 Example 6

(Evaluation Results)

In Examples, the void ratios in the inner areas of the secondaryparticles were at least 5%, and the void ratios in the outer areasthereof were up to 1.5%. In addition, the secondary batteries (forevaluation) obtained by using the positive electrode active materialsobtained in Examples had high initial discharging capacity and excellentcycle characteristics. In particular, those having the void ratio of upto 20% in the inner area of the secondary particle acquired high initialdischarging capacities of at least 168 mAh/g.

In Comparative Examples 1 and 2, the void ratios in the outer areas ofthe secondary particles were up to 1.5%, but the void ratios in theinner areas thereof were less than 5%; and thus, sufficient cyclecharacteristics were not able to be obtained.

In Comparative Example 3, because the void ratio in the inner area ofthe secondary particle was at least 5%, the cycle characteristic wasgood; but, because the void ratio in the outer area was more than 1.5%,the initial discharging capacity was low.

In Comparative Examples 4 to 6, the void ratios in the inner areas ofthe secondary particles were less than 5%, and the void ratios in theouter areas thereof were more than 1.5%; and thus, the initialdischarging capacities were low, and sufficient cycle characteristicswere not able to be obtained.

As described above, each embodiment and each Example of the presentinvention are explained in detail; however, a person ordinarily skilledin the art could easily understand that various modifications can bemade without substantially deviating from novel items and effects of thepresent invention. Accordingly, all of these modification examples areconsidered to be included in the claims of the present invention. Inaddition, the term used at least once and described with a different butbroad or synonymous term in, for example, the specification or thedrawings can be replaced with this different term in any portion of thespecification or of the drawings. Besides, the composition and action ofthe positive electrode active material for a nonaqueous electrolytesecondary battery are not limited to those explained in the embodimentsand Examples of the present invention; and thus, they can be carried outwith various modifications. Furthermore, Japanese Patent Application No.2016-150621 as well as all the literature cited in this specificationare herein incorporated by reference in their entirety to the extentallowed by law.

INDUSTRIAL APPLICABILITY

In the positive electrode active material according to the presentembodiment, the void ratio distribution of the secondary particle iscontrolled, and therefore, the nonaqueous electrolyte secondary batteryusing this positive electrode active material can have a high initialdischarging capacity and an excellent cycle characteristic. Accordingly,the positive electrode active material according to the presentembodiment can be suitably used as the positive electrode activematerial for the nonaqueous electrolyte secondary battery for a vehicleuse and for a mobile use.

Description of Reference Signs 10 Positive electrode active material 11Lithium-metal composite oxide 12 Primary particle 13 Secondary particle14 Void d Diameter of secondary particle r Radius of secondary particleC Central part R1 First area R2 Second area PE Positive electrode(electrode for evaluation NE Negative electrode SE Separator GA GasketWW Wave washer PC Positive electrode can NC Negative electrode can

1. A method for producing a positive electrode active material for anonaqueous electrolyte secondary battery, the positive electrode activematerial represented by a general formula:Li_(a)Ni_(x)Co_(y)Mn_(z)M_(t)O_(2+α) (0.95≤a≤1.50, 0.30≤x≤0.70,0.10≤y≤0.35, 0.20≤z≤0.40, 0≤t≤0.1, x+y+z+t=1, and 0≤α≤0.5; and Mrepresents at least one element selected from Ti, V, Cr, Zr, Nb, Mo, Hf,Ta, Fe, and W) and containing a secondary particle formed of a pluralityof flocculated primary particles, the method comprising: acrystallization process of crystallizing a nickel-cobalt-manganesecomposite hydroxide by neutralizing a salt containing at least nickel, asalt containing at least cobalt, and a salt containing at leastmanganese in an aqueous reaction solution; and a firing process offiring a lithium mixture obtained by mixing the nickel-cobalt-manganesecomposite hydroxide with a lithium compound in an oxygen atmosphere toobtain a lithium-metal composite oxide, wherein in the crystallizationprocess, an oxygen concentration in an atmosphere above a solutionsurface of the aqueous reaction solution is controlled in a range of atleast 0.2% by volume and up to 2% by volume, a temperature of theaqueous reaction solution is controlled in a range of at least 38° C.and up to 45° C., a pH value of the aqueous reaction solution iscontrolled in a range of at least 11.0 and up to 12.5 based on solutiontemperature of 25° C., and a dissolved nickel concentration in theaqueous reaction solution is controlled in a range of at least 300 mg/Land up to 900 mg/L.
 2. The method for producing a positive electrodeactive material for a nonaqueous electrolyte secondary battery accordingto claim 1, wherein the crystallization process includes continuouslyadding a mixed aqueous solution including nickel, cobalt, and manganeseinto a reaction vessel, and overflowing slurry includingnickel-cobalt-manganese composite hydroxide particles formed byneutralization to recover the particles.
 3. The method for producing apositive electrode active material for a nonaqueous electrolytesecondary battery according to claim 2, wherein in the crystallizationprocess, concentration of the mixed aqueous solution ranges from atleast 1.5 mol/L and up to 2.5 mol/L.
 4. The method for producing apositive electrode active material for a nonaqueous electrolytesecondary battery according to claim 1, wherein in the firing process,firing is carried out at a temperature of at least 800° C. and up to1000° C.
 5. The method for producing a positive electrode activematerial for a nonaqueous electrolyte secondary battery according toclaim 1, wherein in the firing process, lithium hydroxide, lithiumcarbonate, or a mixture of these is used as the lithium compound.